Motor operated spool

ABSTRACT

A spool with a hub to carry a spooled hose or cable and first and second couplings to attach the spool to a cradle, wherein the first coupling is arranged to be fixed against rotation as the hub rotates and the second coupling is arranged to rotate in unison with the hub and wherein a drive unit is fitted between the first coupling and the hub to drive the hub around the first coupling and thereby wind the hose or cable around the hub.

TECHNICAL FIELD

The present invention generally relates to spools for winding cable, hose, rope or some other rope like object, and in particular to a spool operated by an electric motor.

RELATED APPLICATION

This application claims the benefit of priority from Australian Patent No 2013242793, the contents of which are incorporated in entirety by reference.

BACKGROUND

Spools, or rewind reels, operated by an electric motor are preferred for winding and storage of hoses and cables. These spools save time and do not require physical effort to wind the cable for storage after use. Another advantage is that they can be adapted to operate via a remote control device to enable the winding of the cable from a position other than at the reel device.

Prior art electric spools are produced for this purpose but they are relatively large, heavy or bulky, taking up more space than traditional spools and therefore eliminating their ability to be used on small equipment such as 12 volt weed and pesticide sprayers. These spools also require the use of high current dedicated electrical wiring on vehicles as they are commonly used in mobile applications.

Currently known electric motor operated spools all employ a drum or cylinder for storing the coiled cable or hose and an electric motor separate from the spool. The motor rotates the spool through some form of gearing or reduction mechanism so that the hose becomes wrapped around the spool at a rate that is safe. Various methods are employed to transfer the rotating movement from the motor to the spool, all of which have their inherent drawbacks.

Some prior art drive methods include:

Belt and pulley system—this system poses a potential safety hazard if left uncovered and requires a belt tensioning or adjusting device. The belts will slip if they are not maintained causing failed operation;

Chain and sprocket system—if uncovered, this system poses the same problems as the belt and pulley system and it generates more noise;

Direct connected open gears—this system is similar to the chain and sprocket system, but is more difficult to cover for safety. The motor must also extend outside the spool width, thereby taking up more space;

Direct connected motor/gearbox unit to spindle that supports the spool—this system significantly adds to the overall width of the spool assembly; and

Direct gear drive to hub assembly that supports the spool on one side (see for example Australian Patent 2005231518)—this system requires heavy framework, hub bearings and a shaft to support the spool, resulting in a heavy finished product.

The reference in this specification to any prier publication for information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

BRIEF SUMMARY

The present invention seeks to provide a compact, economical, electric motor operated spool.

In accordance with the invention, there is provided a spool with a huh to carry a spooled hose or cable and first and second couplings to attach the spool to a cradle, wherein the first coupling is arranged to be fixed against rotation as the hub rotates and the second coupling is arranged to rotate in unison with the hub and wherein a drive unit is fitted between the first coupling and the hub to drive the hub around the first coupling and thereby wind the hose or cable around the hub.

Preferably, the drive unit is an electric motor at least partially recessed in the hub.

Preferably, the motor includes a stator component fixed relative to the first coupling and a rotor component keyed for rotation with the hub.

Preferably, an outer housing of the motor is fixed to the rotor component.

Preferably, the housing includes a flange element fixed to a first side of the spool, to loci the rotor and hub together for rotation in unison.

Preferably, the motor is substantially housed within the hub.

Preferably, the first coupling is in the form of a shaft with a first end projecting from the first side of the spool, for receipt in a first mount of the cradle.

Preferably, the second coupling includes a rotary coupler that has an inlet, an outlet, a gallery that provides fluid communication between the inlet and outlet, and a swivel that allows relative rotation between the inlet and the outlet, wherein the outlet provides a connection for a hose carried by the spool and the inlet provides a connection for a supply line to allow fluid to pass between the supply line and the hose.

Preferably, the gallery and outlet are formed in a body of the coupler that is mounted to a second side of the spool, for rotation in unison with the hub.

Preferably, the body supports a bearing for a second end of the shaft, that extends through the motor and toward the second side of the spool, the bearing allowing relative rotation between the second coupling and the shaft.

Preferably, the second coupling includes an extension piece that is supported in a bearing assembly used to mount the second coupling in a second mount of the cradle.

In another aspect, there is provided a spool assembly including a spool, as described above, and a cradle with first and second mounts arranged to support the first and second couplings of the spool.

Preferably, the spool assembly further includes a hose or cable wound onto the hub of the spool.

Preferably, the cradle includes a hose guide.

Preferably, the spool can be remotely operated.

BRIEF DESCRIPTION OF FIGS.

Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying drawings, in which:

FIG. 1 illustrates an exploded isometric view of a preferred embodiment of the invention showing the motor and first side of the spool;

FIG. 2 illustrates an exploded isometric view of a preferred embodiment of the invention showing the second side of the spool;

FIG. 3 illustrates a cross section of a preferred embodiment of the invention;

FIG. 4 illustrates an isometric view of an assembled spool according to the current invention;

FIG. 3 illustrates a cross section of an alternative embodiment of the invention including hose attachments;

FIG. 6 illustrates an exploded isometric view of the spool of FIG. 5;

FIG. 7 illustrates an isometric view of the spool of FIG. 6 in an assembled condition;

FIG. 8 illustrates an isometric view of an alternative embodiment of a spool, including converging sides and a hose guide;

FIG. 9 illustrates a top view of the embodiment from FIG. 8;

FIG. 10A illustrates a front view of the embodiment from FIG. 8;

FIG. 10B illustrates a hose guide;

FIG. 11 illustrates a side view of the embodiment from FIG. 8;

FIG. 12 illustrates a rear view of the embodiment from FIG. 8;

FIG. 13 illustrates a second side view of the embodiment from FIG. 8;

FIG. 14 illustrates a second isometric view of the embodiment from FIG. 8;

FIG. 15 illustrates a third isometric view of the embodiment from FIG. 8;

FIG. 16 illustrates a fourth isometric view of the embodiment from FIG. 8; and

FIG. 17 illustrates a fifth isometric view of the embodiment from FIG. 8.

PREFERRED EMBODIMENTS

The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

In the Figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts.

Throughout the specification the term cable is intended to include any type of cable or similar object including, but not limited to, various different types of cable, hose, rope, or any other rope-like object.

Referring to FIG. 1, a preferred embodiment of a spool 1 is shown that can be used for winding cable. The spool 1 includes a first side 2, a second side 3 and a central hub 4.

The spool 1 is mounted on a cradle 5 that includes a first mount 6, a second mount 7 and a base plate 8. The two side mounts 6, 7 may be joined by welding or bolting or any other suitable arrangement to the base plate 8, forming the support mechanism to suspend the spool 1. The spool 1 and cradle 5 together form a spool assembly 9.

A motor 10 is arranged to it into a recess 11 formed in the side 2. The motor 10 includes a cylindrical outer housing 12 with a flange 13 for attaching the motor 10 to the side 2, via fasteners 14. The motor 10 also has a shaft 15 with a first end 16 for receipt in a bracket 17 of the first mount 6. The shaft 15 forms a first coupling 20 of the spool 1.

In a preferred embodiment the motor 10 is a brushless direct current (DC) electric motor. A brushless DC motor has many advantages over conventional brushed DC motors, including, but not limited to, longer life and higher reliability, higher efficiency, no radio frequency interference due to brush commutation, linear torque/current relationship, smooth acceleration or constant torque and low cost to manufacture.

The motor 10 operates by providing a torque that rotates the housing 12 and flange 13 relative to the shaft 15, to thereby rotate the hub 4. Since the spool 1 has the motor 10 mounted within it, the motor housing 12 becomes an integral part of the spool 1. When fixed to the spool 1 via the flange 13, the first end 16 of the shaft 15 projects from the side 2 of the spool 1, for receipt in the mount 6. As the motor 10 is an integral part of the spool 1, the shaft 15 becomes a load carrying element for one side of the rotating spool 1.

The shaft 15 is also designed to be fixed against rotation which means no bearing is needed between the mount 6 and the coupling 20, In a preferred embodiment a bolt 21 is used to secure the shaft first end 16 to the bracket 17 and to prevent it rotating.

Referring now to FIG. 2, a second coupling 22 is shown. The coupling 22 includes a generally cylindrical body 23 that is fixed to the second side 3 of the spool 1 such as by bolts 23 a, to rotate in unison with the hub 4. The body 23 includes an extension piece 24 that is supported by a bearing assembly 25 and bracket 18 used to mount the second coupling 22 to the second mount 7.

Referring now to FIG. 3, the second coupling 22 supports a bearing 27, internally of the spool 1, for receipt of a second end 26 of the shaft 15. The second coupling 22 thereby supports the second side 3 of the spool 1 on the mount 7 while still allowing the spool 1 and hub 4 to rotate freely when the motor 10 operates. More particularly, the first side 2 is supported on the first mount 6 by the fixed shaft 15 of the first coupling 20 and the second coupling 22 supports the second side 3 on the second mount 7 via bearing assembly 25. This arrangement has a benefit that the side 2 can be of lighter construction as radial loads are distributed through the spool 1 so as not to deflect side 2 or affect the alignment of shaft 15. Of course, alternative arrangements are possible where, instead of supporting a second end of the shaft 15, a single ended shaft motor is used, which is connected only to the first coupling.

FIG. 3 also shows the cross section of the motor 10. The motor 10 includes a stator component 28 and a rotor component 29. The stator component 28 is fixed on the shaft 15 while the rotor component is designed to rotate about the shaft 15 on bearings 30. The outer housing 12 is fixed to the rotor component 29 such that rotational drive provided by the motor 10 causes the hub 4 to rotate, since the hub 4 and housing 12 are keyed together for rotation in unison by the fasteners 14.

The motor 10 is controlled by a brushless DC motor controller (not shown) to allow it to operate from a vehicle battery of either 12 or 24 volts, or any other suitable power source. The motor 10 may also be configured to be controlled remotely. Although a brushless DC motor is preferred, any other suitable motor or equivalent drive unit can instead be used. For example, a geared motor may be used instead of the brushless motor 10 described above.

In any case, it is apparent from FIGS. 3 and 4 that the motor 10 is at least partially housed within the hub 4 and, preferably, substantially entirely housed inside the spool 1 so that the housing 12 only projects from the side 2, to a minimal extent. The spool 10 is thereby provided with a neat and compact appearance without any exposed componentry that might otherwise present a danger or hazard.

Referring now to FIG. 5, a hose 31 is shown wound/spooled around the hub 4. The second coupling 22 is modified to include a rotary coupler 32. The coupler 32 includes an outlet 33 for connection to the hose 31, an inlet 34 for connection to a supply line 35 and an internal gallery 36 to provide fluid communication between the inlet 34 and outlet 33. The outlet 33 and gallery 36 are formed in the body 23 of the coupling 22, which rotates in unison with the hub 4. A swivel 37 allows the inlet to remain stationary and in communication with the gallery 36 when the spool 1 rotates.

The supply line 35 may be used to provide water to the hose 31. Alternatively, the coupler 32 may be used to supply any other form of liquid or gas, as required.

Referring to FIGS. 6 and 7, the spool assembly 9 is shown respectively in an exploded view and an assembled form where the hose 31 is connected to the outlet 33 of the coupler 32, through an opening 38 in the side 3 of the spool 1. As the spool 1 is rotated, to either wind the hose 31 on or off the spool 1, the outlet 33 and opening 38 will rotate in unison, while the swivel 37 allows the inlet to remain fixed relative to the mount 7.

Referring to FIG. 8 an alternative example embodiment is shown that includes converging spool sides 2, 3 and a hose exit 40 with a hose guide 41. FIG. 9 shows a top view of this embodiment, illustrating the narrow opening between the spool sides 2, 3 and the alignment with the hose guide 41. The converging spool sides 2, 3 cooperate with the hose guide 41 and protect the stored hose 31 from excessive exposure to the elements.

The hose guide 41 enables the operation of the spool assembly 9 via a remote control device. A system to guide the hose 31 onto the spool 1 is required as the operator may be positioned away from the spool assembly 9.

In one embodiment, such as that shown in FIG. 10A, the hose guide 41 is in the form of a tubular bush with a radiused lead-in. The relationship between the length and diameter of the bore is such that the natural curvature of the hose 31 creates a slight resistance to draw through of the hose 31. This eliminates the need of a brake on the spool 1 to prevent unintended dc-spooling. When the hose 31 is pulled it is straightened and this resistance is reduced.

In another embodiment, the hose guide 41 is as shown in FIG. 10B. This hose guide 41 includes a body 42 with four concave rollers 43 spaced apart to create an opening 44 through which the hose 31 passes. The rollers 43 are spaced such that the natural curvature of the hose 31 creates a slight resistance to draw through of the hose 31. Once again this eliminates the need of a brake on the spool 1.

In some example embodiments, the spool assembly 9 provides the ability to recharge the battery during manual de-spooling of the hose 31. As the hose 31 is pulled out the rotation of the spool 1 is used to generate electricity, preferably using the motor 10, to charge the batteries that power the rewind. This is of particular benefit when using a standalone rechargeable battery without continual charging capabilities, such as when used with a combustion engine powered pump that is manually started and does not have its own battery, for example.

Preferably, the remote control will incorporate variable rewind speed selection. Also preferably, the spool assembly 9 will incorporate an audible and/or visual warning of the pending operation of the spool 1 for safety purposes.

Referring to FIGS. 8 to 17, the embodiment shown includes a base plate 8 with a number of different faces, as well as an additional bracket 8 a. This design of the base plate 8 and bracket 8 a provides the ability to mount the spool assembly 9 onto a horizontal surface, a vertical surface or even overhead. Preferably, the major components of the frame are formed by the assembly of two identical pressed or folded sheet metal components, thereby simplifying production.

Referring still to FIGS. 8 to 17, this alternative embodiment also includes a recess 45 in the first side 2 (see FIGS. 14 and 15) and a recess 46 in the second side 3 (see FIG. 17). This allows the portion of the spool 1 outside the hub 4 to be as wide as possible within the frame and therefore hold as much hose 31 as possible, yet still allows the motor 10 or other components to protrude from the sides 2, 3 if necessary.

Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention. 

The claims defining the invention are as follows:
 1. A spool with a hub to carry a spooled hose or cable and first and second couplings to attach the spool to a cradle, wherein the first coupling is arranged to be fixed against rotation as the hub rotates and the second coupling is arranged to rotate in unison with the hub and wherein a drive unit is fitted between the first coupling and the hub to drive the huh around the first coupling and thereby wind the hose or cable around the hub.
 2. The spool of claim 1, wherein the drive unit is an electric motor at least partially recessed in the hub.
 3. The spool of claim 1, wherein the motor includes a stator component fixed relative to the first coupling and a rotor component keyed for rotation with the hub.
 4. The spool of claim 3, wherein an outer housing of the motor is fixed to rotate with the rotor component.
 5. The spool of claim 4, wherein the housing includes a flange element fixed to a first side of the spool, to lock the rotor and hub together for rotation in unison.
 6. The spool of claim 5, wherein the motor is substantially housed within the hub.
 7. The spool of claim 5, wherein the first coupling is in the form of a shaft with a first end projecting from the first side of the spool, for receipt in a first mount of the cradle.
 8. The spool of claim 7, wherein the second coupling includes a rotary coupler that has an inlet, an outlet, a gallery that provides fluid communication between the inlet and outlet, and a swivel that allows relative rotation between the inlet and the outlet, wherein the outlet provides a connection for a hose carried by the spool and the inlet provides a connection for a supply line to allow fluid to pass between the supply line and the hose.
 9. The spool of claim 8, wherein the gallery and outlet are formed in a body of the coupler that is mounted to a second side of the spool, for rotation in unison with the hub.
 10. The spool of claim 9, wherein the body supports a bearing for a second end of the shaft, that extends through the motor and toward the second side of the spool, the bearing allowing relative rotation between the second coupling and the shaft.
 11. The spool of claim 10, wherein the second coupling includes an extension piece that is supported in a bearing assembly used to mount the second coupling in a second mount of the cradle.
 12. A spool assembly, including the spool of any one of claims 1 to 11 and a cradle with first and second mounts arranged to support the first and second couplings of the spool.
 13. The spool assembly of claim 12, further including a hose or cable wound onto the hub of the spool.
 14. The spool assembly of claim 12, wherein the cradle includes a hose guide.
 15. The spool assembly of claim 14, wherein the spool can be remotely operated. 